crimp to crimp

EN

TOP PERFORMANCEIS OUR CONNECTION TO THE FUTURE.

Best in class productivity

– High machine speed for the best unit

cost performance

– Fastest conversion for maximum

production output

– First-time-right: perfectly synchronized

machine processes with excellent

CPK results

Powerful and flexible

– Robust and reliable processing of wire

cross sections ranging from 0.13 to 6 mm²

– Produces special and complex applications

thanks to flexible machine configuration

Ready for the future

– Most modern, forward-looking machine

technology for highest requirements

– Integrated automatic conductor detection

(ACD) for superb quality stripping

– Equipped for future requirements thanks to

quality monitoring and gentle wire processing

Consistent high productivity and flexibility with

maximum precision are the requirements

fully automated wire processing has to meet,

both today and in the future. The Alpha 550 –

the latest fully automatic crimping machine for

two-sided seal loading – meets these require-

ments across the entire spectrum with revo-

lutionary technology. The Alpha 550 can yield

crucial competitive advantages with its un-

matched unit cost performance, flexible produc-

tion output and superb quality. The machine

comes with an ACD automatic conductor de-

tector as a standard feature.

Double sideAbsolutely precise processing with double blade head and automatic conductor detec-tor (ACD).

MAXIMUM PERFORMANCE

S1440SEAL MODULE

Q1240STRIP QUALITY CHECK

At high speed for top unit

cost performance

With its high processing speed, the Alpha

550 achieves the best unit cost perfor-

mance in its class. All system components

are designed for top performance. The

conveyor belt speed in the new deposit

system is automatically adjusted to ensure

consistent optimum throughput.

Ultra-fast conversion

for maximum productivity

Simple, fast setup and conversion ap-

proaches allow short travel paths while ac-

celerating the conversion and setup pro-

cedures. With the touch screen, keyboard

and mouse, the Alpha 550 can be oper-

ated in a time-saving and ergonomic fash-

ion. The TopWin software allows the next

job to be edited without halting operations

and the material and the tool to be pre-

pared. Indicator lamps and LED-illuminated

work zones optimize and expand user

guidance.

THE STRONGEST IN ITS CLASS

C1370CRIMP MODULE

01

02

MAXIMUM PERFORMANCE HAS NEVER BEEN

MORE FLEXIBLE AND MORE ROBUST.

01The robust swivel arm with its un-beatable repeat accuracy supports stable wire processing.02Highly effective option: quick-change wire draw-in.03Quick and reliable setup directly on the crimping module.

03

First-time-right approach

for almost no rejects

Perfectly synchronized machine processes

and quality assurance and monitoring func-

tions ensure top precision and excellent

CPK results. Processes are optimum thanks

to the reliable EtherCAT technology.

Robust system and versatile options

With the reliable TopWin software you can

record and edit jobs while the machine

is running. Powerful servomotors position

the swivel arm with unrivaled repeat ac-

curacy. The mechanical and electronic com-

ponents are well-protected from dirt and

ambient influences and also suitable for en-

vironments with high temper atures and

moisture. Options such as the linear quick

wire changer and the quick MTC mobile

terminal changer for fast crimp tool chang-

es, the lockable tool drawer and various

other features enable optimal flexible oper-

ation within the stable system.

Customer-specific and individualized

The different processing modules make it

possible to have complex and individual-

ized configurations with up to four stations.

Customer-specific processes can be pro-

grammed with the help of licenses.

The market leader’s

quality and expertise

Komax Wire assures the maximum per-

formance capability of the system by deliv-

ering holistic, comprehensive quality. It

considers all components and rounds out

these efforts with local services globally.

Q1240 strip quality check

for maximum quality

The Q1240 quality tool runs an optical

check on stripping quality and automatic-

ally separates out defective products.

It assures traceable quality with statistics,

saved images and WPCS. Compared

to the option CPS (cut pulled strands), it

boosts the output rate by as much as

10 percent.

C1370 crimping module

for maximum productivity

Shortest setup and conversion times are

achieved thanks to efficient user guidance

with cable positioning directly on the mod-

ule. CFA+ assures the highest level of quali-

ty and the lowest possible rate of rejects.

Productivity can be increased substantially

in connection with the time saved.

S1440 seal module

for maximum flexibility

The module automatically loads seals on

the cables, namely all the usual varieties of

seals including mini-seals. Precision me-

chanics combined with seal position moni-

toring ensures a high degree of process

reliability. The module can be converted

quickly from one variety of seal to another,

which greatly boosts productivity.

The efficient belt drive reliably draws in the cable at a speed of up to 12 m/s. A pneumatic

or mechanical setup module is optionally available.

Technical data

Wire cross sections 0.13 – 6 mm² (AWG 26 – 12)*

Wire draw-in speed Max. 12 m/s (39 ft/s)

Outside diameter of conductor Max. 5.1 mm (0.20 in)

Length range 60 – 65 000 mm (2.35 in – 213 ft)

Full strip 0.1 – 29.5 mm (0.004 – 0.98 in)

Half strip Max. 35.5 mm (1.4 in)

Crimp force 1 – 22 kN (224 – 4 496 lbf)

Processing stations side 1 / 2 2 / 2

Noise level < 80 dB (without crimp tool)

Electrical connection 3 × 208 – 480 V / 50 – 60 Hz / 5.6 k VA

Compressed air connection 5 – 8 bar (73 – 116 psi)

Air consumption Crimp / Crimp Seal crimp / Seal crimp

<7 m³/h (247 ft³/h) <11 m³/h (388.5 ft³/h)

Weight (incl. 2 crimping modules) 1.30 t (2866 lb)

* Depends on material out of which the cable is made.

Uniform guide tubes support optimized cable handling for the thinnest cables from 0.13 mm² to 6 mm².

The tools are within reach at any time in the practical, lockable drawer situated directly under wire draw-in.

1525

mm

(60

in)

Basic wire deposit module 2 m: 3825 mm (150.6 in)Basic wire deposit module 4 m: 5770 mm (227 in)

Height with cover closed: 1790 mm (70.5 in)Height with cover completely open (maximum opening): 2790 mm (109.8 in)

The finished cables are placed gently in the smooth deposit unit made of stainless steel.

Effective output rate

FLRY conductors 0.5 mm² (AWG20)

Wire draw-in speed 12 m/s

Crimping module C1370

Seal module S1440

Crimp force analysis Active

ACD, Q1240 Inactive

Deposit gripper Active

The actual output rate can vary with application and machine configuration.

Crimp / Crimp

Crimp / Seal

Seal / Seal0

1000

2000

3000

4000

5000

6000

0 500 1000 1500 2000 2500 3000 3500 4000

wire length [mm]

pcs

/h

Cutting to length

Cutting pulled strands

Stripping with full strip

Stripping with half strip

Flat cable / notching

Processing of inner conductors

Double casing, coaxial and triaxial cables

Intermediate stripping

Crimping

Double crimping

Options and accessories

Automatic delivery systems

Komax 106 • ads 119 • ads 123 • F1150

Marking systems Komax 26 hot-stamp marker • Komax IMS inkjet marking systems • Laser marking on request

Processing modules C1370 crimping module • S1440 seal module • mci 782 twisting module • ioc 785 tinning module • mci 792 sleeve insertion module • Double gripper module • AEH ferrule module • MIL crimp module • Welding module • Ultrasonic compaction

Quality control Integrated crimp height measurement • Integrated pull-out force measurement • Q1240 strip quality check • Material change detection • Material verification • Splice detection • Q1140 spark tester • SPM seal position monitoring • Terminal end monitoring

Deposit systems Basic module 2 m (78.7 in) or 4 m (157.5 in) Extension module 2 m (78.7 in) or 4 m (157.5 in)

Accessories Quick tool changing system • PM8300 bar code scanner

Software WPCS networking interface • TopConvert data conversion • Komax CAO control center

Processing examples

Double stroke function for closed terminals

Seal loading

Twisting / tinning

Sleeve insertion

Ferrule crimping

MIL crimping

Wire-end compaction, splicing, welding

Hot-stamp marking

Inkjet marking

komaxwire.com

Komax AGIndustriestrasse 66036 Dierikon, SwitzerlandPhone +41 41 455 04 55Fax +41 41 450 15 79

Komax Wire – industry leader today and in the future

As the pioneer and market leader in automatic wire processing,

Komax Wire supplies its customers with innovative solutions fit for

the future in all areas calling for precise terminal connections.

Standardized and customer-specific machines are supplemented

by various processing modules, individual application parts as

well as suitable software and interfaces to achieve safe, efficient

production. Development and production are carried out within

the globally active Swiss company at different locations. A compre-

hensive sales and service network supports customers with

standardized service processes in more than 50 countries locally

on site, ensuring the availability and sustainable value of their

investments after commissioning. The Swiss company Komax

Wire is part of the globally operating Komax Group with about

1,500 employees.

Market segments

Komax Wire offers outstanding com-

petence and solutions for various areas

of application and draws on them to

generate the desired value-added for

the entire process and optimize eco-

nomic efficiency in line with customer

requirements. The main markets of

Komax Wire are as follows: automotive,

aerospace, industrial and telecom &

datacom. With this breadth of expe -

ri ence, customers obtain expert knowl-

edge for process optimization and

access to the latest technologies.

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